Introduction of Product
Introduction of Hydraulic Excavator PC200-8
The newly introduced medium sized hydraulic excavator PC200-8 was developed with the focus on
Environment, Safety and IT. The background of the development, technology used and features of the
product are described below.
Key Words: PC200-8, environmental friendliness, Tier 3, next-phase exhausted gas regulations, low noise,
safety, protective structure cab for operator at roll over, IT, large liquid crystal color monitor,
KOMTRAX
1. Introduction
The PC200 series including its family models comprise
the leading products of Komatsu accounting for more than 10%
of the total sales of Komatsu globally.
The hydraulic excavator PC200-7 was introduced to
market in 2001 and has since then been enjoying a good
reputation in the market. Recently, demands for a reduction
in environmental load are increasing, and next-phase exhausted
gas regulations will be enforced sequentially in Japan, the
United States and Europe. In EU countries, Stage 2 noise
regulations will start beginning 2006. With the focus on
Fig. 1 Development concepts
Photo 1 PC200-8
2005 VOL. 51 NO.156 Introduction of Hydraulic Excavator PC200-8
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Masafumi Tsuji
Tomio Teranaka
Environment, Safety and IT, the Dantotsu, unique and
unrivaled, product PC200-8 as outlined below has been
developed and put on the market conforming to various
regulations and featuring many selling points (Fig. 1, Photo 1).
2. Development Objectives
Selecting Environment, Safety and IT as develop-
ment concepts, the development objectives are to conform to
environmental regulations, to pursue reduction in environ-
mental load, safety and comfortableness, to enhance IT utiliza-
tion and maintainability, and to upgrade the marketability, in
order to develop hydraulic excavators suiting user needs. The
development objectives are summarized below.
(1) Environmental friendliness
Conformance to next-tier exhausted gas regulations of
Japan, the United States and Europe
CO2 emission reduction (fuel consumption 10% reduction)
Guidance messages urging energy-saving operations dis-
played on the monitor panel
Eco gauge
Idling stop caution
Reduction in exterior noise
Compliant with the super low noise construction machinery
specified by the Ministry of Land, Infrastructure and
Transport of Japan
Compliant with EU Stage 2 noise regulations
(2) Safety and comfortableness
To develop a global product seeking safety design and
comfortableness, clearing strict safety standards of the world,
incorporating:
Protective structure cab for operator at roll over
Anti-slip components toward passage
Large side and rearview mirrors (Compliant with new draft
ISO standard)
Rearview monitor (Option)
 Noise inside cab equal to that in a passenger car [Low fuel consumption]
[Low noise]
High pressure common rail
Armrest monoblock with console High pressure common rail Low drive torque of supply pump
High pressure injection Low fuel noise by pilot injection
(3) IT Multistage injection Rear gear train
Injection time control Low gear noise
To further advance the IT technology of PC200-7 to pro- Advanced combustion technology Tappet cover eliminated, monoblock structure
Deterioration in fuel consumption Vibration of cover portion curbed by enhanced
vide more information that is easier to see and easier to curbed by low NOx technology rigidity
4 valves/cylinder High rigidity cylinder block
use. Vibration curbed by a rib and by the changing
[Emission] shape of the skirt portion
A new large liquid crystal multi-screen monitor 4 valves/cylinder
Function switches Larger air intake
Center injection Common rail
Air conditioner switches and display contained on the Uniform fuel spray
(Facilitates fuel/air mixing)
monitor panel High pressure common rail
High pressure injection ratio
Reinforced KOMTRAX functions Multistage injection
Injection time control
(4) Enhanced maintainability Advanced combustion technology
Low NOx technology
Vehicle easier to maintain Regulatory control conformed
without ECR
A gas damper cylinder used with the hood
Easy cleaning of coolers (Side-by-side cooling) Engine mount ECM Rear gear train
Fuel prefilter (With water separator)
Hydraulic pilot filter (Attachment specification only) Fig. 2 Technologies incorporated in the engine
Remote oil draining of swing machinery
The fuel consumption efficiency (production volume per fuel
consumption) increased by about 10 to 15% (Table 2).
3. Selling Points The engine itself met the exhausted gas regulations, and
The selling points of the PC200-8 and technologies to ac- fuel consumption was reduced at the same time. Losses of
complish them based on the foregoing are described. the hydraulic system were reduced by controlling flow merging
3.1 Environment and dividing and by using a quick return circuit. Matching
3.1.1 Compliant with next-tier exhausted gas control of the engine and hydraulic pump was optimized by
regulations electronic control. The efficiency of the hydraulic component
was improved.
The next-tier exhausted gas regulations and years of en-
forcement for Japan, the United States and Europe for the Table 2 Comparison of fuel consumption and
PC200 class vehicles are as follows (Table 1). fuel consumption efficiency
PC200-8 PC200-7
Table 1 Next generation exhaust gas regulations Damp loading
Work amount 100 100
Control value; NOx/HC/PM*(NOx+NMHC)/PM(g/kWh)
Fuel consumption 90 100
Current regulation Next generation regulation
Fuel economy 111 100
Ditch digging Work amount 104 100
Regulation Regulation
enforcement
Control
enforcement Control value
Fuel consumption 90 100
value Fuel economy 116 100
period period
(Figures are shown basing Mode A of Type 7 as 100. Type 8 is for Mode P)
Japan 03/10 6.0/1.0/0.3 07/10 3.6/0.4/0.2
USA 03/1 *6.6/0.3 07/1 *4.0/0.3
Europe 03/1 6.0/1.0/0.3 07/1 *4.0/0.3
3.1.3 Eco gauge and idling stop caution
To meet the foregoing exhausted gas regulations, the A gauge to show the fuel consumption status of the
SAA6D102 engine of Type 7 was modified and was developed machine is displayed on the right-hand side of the
as the SAA6D107 engine with a larger piston displacement. multi-monitor screen. The gauge zone changes from green to
High injection pressure can be obtained by using an electroni- orange to notify the operator of when the load status changes to
cally controlled high-pressure fuel injection system (High a high load status (Fig. 3).
Pressure Common Rail - HPCR), allowing the random control Fuel consumption state displayed on an
indicator Eco Gauge
of multi-stage injection and injection time. Tuned to the
increase in the intake airflow rate, the number of intake and
exhaust valves has been increased to four per cylinder. The
High
injection nozzle is placed in the center of the cylinder to obtain
uniform fuel injection. Low NOx and low PM are accom-
Fuel
plished by optimizing the shape of the combustion chamber. consump-
In addition to the technology that achieved low emissions, tion
technologies incorporated in the engine are described below Low
together with the technologies that lowered fuel consumption
and noise (Fig. 2).
3.1.2 Low fuel consumption
Actual fuel consumption (l/h) was reduced by 10% in ex- The green zone is an ideal model for
cavation and loading onto dump trucks and in ditch digging energy saving operation
jobs in Mode P compared with Mode A conducted with Type 7. Fig. 3 Eco Gauge

2005 VOL. 51 NO.156 Introduction of Hydraulic Excavator PC200-8

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 If an idling state continues longer than a preset duration, 3.2 Safety and comfortableness
a message will be displayed on the monitor urging the operator In addition to the safety and comfortableness design im-
to stop idling (Fig. 4). plemented in the past, the following new technologies are
incorporated to enhance the safety and comfortableness of the
Displayed when idling continues operator.
3.2.1 Protective structure cab for operator at
roll over
Accidents by roll over account for a large portion of acci-
dents to operators of hydraulic excavators. Protection of the
operator in roll over is very important for operator safety.
The strength of the cab of the PC200-8 has been significantly
Please avoid idling increased to protect the operator in roll over. A new cab with
a pipe-structure frame is used. The new cab minimizes cab
deformation in roll over to a certain range, to protect the opera-
tor inside, ensuring operator safety even if the vehicle rolls
over one turn (Fig. 6).
Fig. 4 Display screen calling for the elimination of engine idling

3.1.4 Low exterior noise

The PC200-8 conforms to the super low noise construc-
tion machinery specified by the Ministry of Land, Infrastruc-
ture and Transport of Japan and EU Stage 2 noise regulations.
PC200-class vehicles need to be 100 dB (A) or less to meet the
specifications of the Ministry of Land, Infrastructure and
Transport of Japan, and 102 dB (A) to meet the EU Stage 2
noise regulations.
A newly developed engine itself achieved noise reduction.
Pipes are used Push test
HPCR enabled multi-stage fuel injection and a reduction in
combustion noise. A rear gear train reduced gear sound. Fig. 6 Cab of protective structure for operator
Vibration was curbed using a high-rigidity cylinder block
(Fig. 2). 3.2.2 Anti-slip floor plate
To achieve both heat balance and low noise, a large In addition to sandpaper-type floor plates that are placed
side-by-side cooling unit was newly developed. The fan in conventional models, anti-slip floor plates with small protru-
rotating speed is reduced by about 10% to lower the fan opera- sions that are durable and safer are placed on passages all over
tion sound. the machine cab (Fig. 7).
The muffler is made low noise, and a sound cover is in-
stalled to lower sound emitted by the muffler shell. Protrusion-type anti-slip
An exhaust duct is installed in the engine hood. members

Sound-absorbing materials are optimally placed on the vehicle

body.
Through these measures, exterior noise was reduced
(Fig. 5).

Sound-shielding cover around muffler

Exhaust duct

Sandpaper type

Optimum sound
shielding of sound
source
Fig. 7 Anti-slip members

3.2.3 Large side and rearview mirrors

Low fan RPM
A large cooling unit is used
The side mirrors installed on the cab and the right-hand
handrail of the body are made larger. Large mirrors are also
Electronically controlled common rail Low noise muffler
engine
added on the fuel tank and counterweight, allowing safety ade-
Multistage injection quate checks of the right and rear of the body. The rearview
High rigidity cylinder block Optimum layout of
Rear gear train sound-absorbing materials monitor is an option described in the following, and these mir-
rors ensure safety around the vehicle. The mirrors meet the
Fig. 5 Low noise technology
new draft safety standard of ISO (Fig. 8).

2005 VOL. 51 NO.156 Introduction of Hydraulic Excavator PC200-8

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 Fig. 9 Noise in cab
New additions
Larger mirrors 3.2.6 Armrest monoblock with console
Fig. 8 Mirror The armrest has been moved from the operator seat to the
console and is provided with a function to adjust its height.
3.2.4 Rearview monitor (Option) The new armrest assures optimum adjustment of the positions
Camera images can be displayed on the multi-screen of the control lever and armrest without depending on the
monitor by changing the screen when a rear camera available operator body size. The same equipment inside the cab that
as an option is connected to the monitor. Images of up to has enjoyed popularity with the PC200-7 because of usability
three cameras can be displayed. The monitor can display one is installed (Photo 3).
screen or two screens by selection. The monitor greatly
contributes to safe operation by the operator (Photo 2). Remotely controlled
intermittent wiper with Drink box
washer
Luggage box
Magazine rack
Cup holder
Defroster

Ashtray
Cigarette AM/FM auto tuning radio
lighter

Armrest monoblock
with console

Photo 2 Rearview monitor Photo 3 Equipment installed in cab and armrest

3.2.5 Cab noise equal to passenger car noise 3.3 IT

level 3.3.1 New large color multi-screen monitor
A noise level equal to that in a passenger car is attained
and switches
for the cab by minimizing the noise of the sound sources and
Use of a color monitor started with the -7 model, but that
by shielding and absorbing sounds (Fig. 9).
on PC200-8 is larger than before and also includes air-
The noise of the engine itself has been minimized, a new
conditioning control function in its display menu for easier
air conditioner has been developed and the noise of the blower
operation (Fig. 10).
motor reduced, a new cab featuring high rigidity and a good
A high-resolution 7-inch TFT (thin film transistor) liquid
sound-shielding effect has been installed, and the sound-
crystal panel offers greatly enhanced visibility.
shielding and absorption effects of the vehicle body have been
New function switches feature the easy operation of vari-
optimized. The PC200-8 has achieved quietness highest in its
ous functions (Fig. 10).
class.

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 The monitor is a multi-lingual monitor, allowing selec-
tion from ten languages (Fig. 11).
The breaker mode now allows the setting of two flow
rates. An attachment mode has been newly included to suit
various attachments. Three flow rates can be set (Fig. 12).
7-inch large
liquid crystal screen
Air conditioning Function switches
display screen
Air conditioner
switches
Fig. 10 Multi-display color monitor and function switches
Fig. 11 Multilingual monitor
3.3.2 Reinforced KOMTRAX functions
The KOMTRAX functions first installed in the PC200-7
have been reinforced further to assure more security and confi-
dence for the user.
KOMTRAX has been developed as a system to store and
control information on vehicle working position by GPS and
status and conditions in a Web server through communication
equipment, and to furnish this data to the user, DB and GR
through the Internet. The system has been useful in determin-
ing vehicle working status from a remote place, timely parts
supply service, delivering machines, determination of a vehicle
fault from a remote place, failure diagnosis and providing ex-
peditious repair service. These functions have been rein-
forced by beefing up the burglarproof function and by adding
2005 VOL. 51 NO.156 Introduction of Hydraulic Excavator PC200-8
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Fig. 12 Attachment mode
data downloading and data delivery through a mobile phone as
well as other functions.
The new burglarproof functions include setting a pass-
word to prevent a third person from starting the engine without
permission, a time reservation lock and a calendar reservation
lock, allowing the setting of an engine start lock (immobilizer).
3.4 Improvement of maintainability
3.4.1 Gas damper cylinder for the hood
Gas damper cylinders are installed to allow easy opening
and closing of the hood to reduce the force required to open
and close the hood (Photo 4).
Gas damper cylinder
Torsion bar
Photo 4 Gas damper cylinder
3.4.2 Easy cleaning of cooling units (Side by
side)
The newly developed side-by-side cooling units allow re-
moval of the radiator, oil cooler, after cooler and other units
independently by removing them upward for easy cleaning
(Fig. 13).
3.4.3 Fuel prefilter
Tuned to the installation of HPCR, a prefilter with a
built-in water separator is installed in addition to the main fuel
filter to enhance fuel cleanliness and to prevent mixing of
water. The prefilter is installed inside the hydraulic pump
room located in the right-hand cover of the vehicle body for
easy operation. A sensor in the water separator detects the
mixing of water, and the information is displayed on the moni-
tor (Fig. 14).
 3.4.5 Remote oil draining of swing machinery
Oil cooler After-cooler
Oil can be drained remotely from the swing machinery to
make oil-draining work easy (Fig. 15).
Radiator

Fuel cooler

Air conditioner capacitor Drain plug

Fig. 13 Side-by-side cooling

Oil remote drain
Fig. 15 Swing machinery
3.4.4 Hydraulic pilot filter
A filter is installed in the hydraulic pilot circuit to meet 4. Conclusion
specifications with attachment piping to enhance the cleanli-
ness of the pilot circuit (Fig. 14). The PC200 series are global machines and the leading
construction machinery of Komatsu. The development of this
series required fine-tuning the timing to match the readiness of
Fuel prefilter Komatsus production corporations of the world to start pro-
Built-in water separator Pilot filter (Available in
(Operation start inspection can be made ATT specification only) duction. Mass production at Komatsus Osaka Plant, the
on the monitor panel) mother plant, was started, and production at plants in the
United States, Europe and Asia was started in parallel. Tran-
sition to smooth production in large quantities is the current
challenge and interest.

Introduction of the writer

Masafumi Tsuji
Entered Komatsu in 1982.
Currently belongs to Construction Equipment
Engine oil filter
Technical Center 1, Development Division,

Tomio Teranaka
Entered Komatsu in 1988.
Currently belongs to Construction Equipment
Technical Center 1, Development Division,

Fig. 14 Fuel prefilter and hydraulic pilot filter

[A few words from the writer]

Komatsu has developed hardware and software of compo-
nents, such as engines, hydraulic components, power lines, con-
trollers, monitors on its own. With the cooperation with Compo-
nent Development Center, the full backing of Osaka Plant, which
is a production factory, and the efforts of project members, we
could achieve the quality target somehow, and clear the dead line
of development, and finally started the mass production.

2005 VOL. 51 NO.156 Introduction of Hydraulic Excavator PC200-8